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IAC Assessment: WV0507
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IAC Assessment: WV0507
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IAC Center West Virginia University
Assessment Year 2015
Principal Product Polypropylene
NAICS 325211 - Plastics Material and Resin Manufacturing
SIC 2821 - Plastics Materials And Resins
Sales $100,000,000-$500,000,000
# of Employees 120
Plant Area (Sq.Ft.) 4,617,000
Annual Production 569,000,000 Pounds
Production Hrs. Annual 8,760
Location (State) WV
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $3,344,327 82,396,800 kWh $0.04
Electricity Demand $1,522,858 137,062 kW-months/year $11.11
Natural Gas $2,285,540 495,713 MMBtu $4.61
TOTAL ENERGY COSTS $7,152,725
RECOMMENDED SAVINGS* $907,840 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $181,157
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes
$ kWh $ kW-months/year $ MMBtu $ gal $ $
01: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$352,153
Cost:
$1,664,938
- - - - $352,153 76,389 - - - - -
-
kWh
-
-
kW-months/year
$352,153
76,389
MMBtu
-
-
gal
-
-
$
02: 2.2121 INCREASE AMOUNT OF CONDENSATE RETURNED Savings:
$161,509
Cost:
$150,000
- - - - $155,509 33,733 $6,000 - - - -
-
kWh
-
-
kW-months/year
$155,509
33,733
MMBtu
$6,000
-
gal
-
-
$
03: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$71,462
Cost:
$301,590
$(-439) (-10,825) $(-167) (-15) $72,068 15,633 - - - - $(-439)
(-10,825)
kWh
$(-167)
(-15)
kW-months/year
$72,068
15,633
MMBtu
-
-
gal
-
-
$
04: 2.4146 USE ADJUSTABLE FREQUENCY DRIVE OR MULTIPLE SPEED MOTORS ON EXISTING SYSTEM Savings:
$90,956
Cost:
$60,015
$66,158 1,629,517 $24,798 2,232 - - - - - - $66,158
1,629,517
kWh
$24,798
2,232
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
05: 2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO Savings:
$53,644
Cost:
$4,100
- - - - $53,748 11,659 - - $(-104) - -
-
kWh
-
-
kW-months/year
$53,748
11,659
MMBtu
-
-
gal
$(-104)
-
$
06: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$49,825
Cost:
$65,562
$36,237 892,527 $13,588 1,223 - - - - - - $36,237
892,527
kWh
$13,588
1,223
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
07: 2.4157 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM Savings:
$32,498
Cost:
$1,000
$25,970 639,651 $9,732 876 - - - - $(-3,204) - $25,970
639,651
kWh
$9,732
876
kW-months/year
-
-
MMBtu
-
-
gal
$(-3,204)
-
$
08: 2.2113 REPAIR OR REPLACE STEAM TRAPS Savings:
$26,405
Cost:
$14,973
- - - - $28,720 6,230 - - $(-2,315) - -
-
kWh
-
-
kW-months/year
$28,720
6,230
MMBtu
-
-
gal
$(-2,315)
-
$
09: 2.4151 DEVELOP A REPAIR/REPLACE POLICY Savings:
$25,719
Cost:
$861
$19,920 490,641 $7,466 672 - - - - $(-1,667) - $19,920
490,641
kWh
$7,466
672
kW-months/year
-
-
MMBtu
-
-
gal
$(-1,667)
-
$
10: 2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS Savings:
$18,016
Cost:
-
$13,105 322,780 $4,911 442 - - - - - - $13,105
322,780
kWh
$4,911
442
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
11: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$15,713
Cost:
$6,794
$11,425 281,398 $4,288 386 - - - - - - $11,425
281,398
kWh
$4,288
386
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
12: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$3,922
Cost:
$278
$2,855 70,319 $1,067 96 - - - - - - $2,855
70,319
kWh
$1,067
96
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
13: 2.2511 INSULATE BARE EQUIPMENT Savings:
$3,273
Cost:
$6,566
- - - - $3,273 710 - - - - -
-
kWh
-
-
kW-months/year
$3,273
710
MMBtu
-
-
gal
-
-
$
14: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$1,967
Cost:
$252
$1,430 35,223 $537 48 - - - - - - $1,430
35,223
kWh
$537
48
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
15: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$778
Cost:
$597
$567 13,976 $211 19 - - - - - - $567
13,976
kWh
$211
19
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
TOTAL RECOMMENDED Savings:
$907,840
Cost:
$2,277,526
$177,228 4,365,207 $66,431 5,979 $665,471 144,354 $6,000 - $(-7,290) - $177,228
4,365,207
kWh
$66,431
5,979
kW-months/year
$665,471
144,354
MMBtu
$6,000
-
gal
$(-7,290)
-
$
TOTAL IMPLEMENTED Savings:
$181,157
Cost:
$34,824
$74,705 1,840,012 $28,001 2,520 $85,741 18,599 - - $(-7,290) - $74,705
1,840,012
kWh
$28,001
2,520
kW-months/year
$85,741
18,599
MMBtu
-
-
gal
$(-7,290)
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ gal $ $
Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes